CN113385639A - Design method of variable wall thickness sand mold structure for controlling microstructure of casting in targeted manner and variable wall thickness sand mold structure - Google Patents
Design method of variable wall thickness sand mold structure for controlling microstructure of casting in targeted manner and variable wall thickness sand mold structure Download PDFInfo
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- CN113385639A CN113385639A CN202110477672.1A CN202110477672A CN113385639A CN 113385639 A CN113385639 A CN 113385639A CN 202110477672 A CN202110477672 A CN 202110477672A CN 113385639 A CN113385639 A CN 113385639A
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Abstract
The invention discloses a variable wall thickness sand mold structure for targeted control of casting microstructure and a manufacturing method thereof, belonging to the field of sand mold casting, wherein an integral sand mold with a variable wall thickness structure is manufactured through numerical simulation calculation and 3DP process design, and on the basis of keeping the structure and strength required by sand mold work, the temperature field during alloy solidification is improved by changing the structure and wall thickness of an external sand box, so that the cooling speed of each part of casting is consistent, the generation of casting defects is avoided, and the uniformity of casting structure and the quality of a casting are improved; meanwhile, the outer sand box is changed into a conformal design, the sand box is not a traditional cubic structure any more, the size of the sand mould is effectively reduced, the raw sand is saved, and the cost is reduced.
Description
Technical Field
The invention belongs to the field of sand casting, and relates to a design method of a variable wall thickness sand mold structure for controlling the microstructure of a casting in a targeted manner and the variable wall thickness sand mold structure.
Background
Sand casting refers to a manufacturing method for producing castings in sand molds, and more than 80% of products in the casting industry are finished by sand casting. Compared with other casting methods, sand casting has the advantages of low cost, simple production process, short production period and wide application alloy variety, so that the sand casting is widely applied to castings with complex space structures, such as engine cylinder bodies, cylinder covers, impellers, blades, transmission case bodies, valve bodies and the like. In the traditional sand casting process, a corresponding mold is required to be prepared according to the shape of a casting, a sand core, an upper sand box and a lower sand box are prepared by adopting the mold respectively, and the sand core, the upper sand box and the lower sand box are further assembled to form a sand mold for casting.
And (3) keeping the temperature of the poured molten metal in a sand mold for a certain time, cooling, and forming the required casting shape. However, in the process of cooling and solidifying the casting, because the upper sand box and the lower sand box are both in a square structure in the traditional sand casting, the wall thickness of each part of the sand mold is inevitably uneven, so that the heat dissipation conditions of each part of the casting are inconsistent when the part with a more complex casting structure is cast, the cooling speed of each part of the casting is inconsistent due to the factors, the casting defects such as shrinkage porosity and shrinkage cavity are easily generated at the part cooled and solidified after the casting, and the microstructure of each part of the casting is uneven, so that the overall performance of the casting is influenced.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a variable wall thickness sand mold structure design method for controlling the microstructure of a casting in a targeted mode and a variable wall thickness sand mold structure.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
the invention discloses a design method of a variable wall thickness sand mold structure for targeting control of a casting microstructure, which comprises the following steps:
1) setting at least 5-10 temperature measurement areas on an outer sand box of a casting sand mold structure to be measured according to the change characteristics of the shape of the casting, and simulating and calculating the simulated temperature data of each temperature measurement area;
2) carrying out an actual casting experiment by adopting the casting sand mold structure to be measured, and measuring actual temperature data of each temperature measurement area in real time;
3) comparing and analyzing the simulated temperature data obtained in the step 1) and the actual temperature data actually measured in the step 2) at the same moment, if the relative temperature error of any temperature measuring point is more than 10%, increasing or decreasing the heat conduction coefficient and the radiation heat exchange coefficient by 10%, and then taking the values as new basic parameters;
4) repeating the steps 1) to 3) until the error between the temperature measuring point data obtained by the simulation calculation and the actually measured temperature at the same moment is less than 10% at all times, and obtaining basic parameters for the simulation calculation;
5) simulating and calculating solidification temperature fields of the outer sand box of the casting to be measured at different moments by using the simulated temperature data of the casting obtained in the step 1) and the basic parameters for simulation calculation obtained in the step 4);
6) analyzing the solidification temperature fields of the casting external sand box to be detected calculated in the step 5) at different moments, and judging whether a local supercooling temperature area exists or not; if the local supercooling region exists, thickening the outer sand box in the local supercooling temperature region, and repeating the steps 1) to 5) until the local supercooling temperature region does not exist; and when the temperature local supercooling area does not exist, storing the corrected thickness data of the outer sand box, namely designing the thickness data of the variable wall thickness sand mold structure.
Preferably, in the step 1), ProCAST software is adopted to carry out simulation calculation of simulation temperature according to the sand mold structure and the alloy basic parameters; wherein, the sand mould structure and alloy basic parameters include: thermal conductivity, radiative heat transfer coefficient, specific heat, latent heat of solidification, density, and solid/liquidus temperature of the alloy.
Preferably, in step 2), real-time measurement is performed on actual temperature data of each temperature measurement area by using a thermocouple thermometry method
The invention discloses an integral sand mold with a variable wall thickness structure, which is an integral structure consisting of an internal integral sand core, an external variable wall thickness sand box and a bottom thickening sand box;
the thickness data of the variable-wall-thickness sand mold structure is obtained by the design method for the external variable-wall-thickness sand mold for processing and manufacturing.
Preferably, the internal integral sand core is a sand core prepared by a 3DP process according to the structure of the casting to be measured.
Preferably, the external variable-wall-thickness sand box is formed by integrally connecting a variable-wall-thickness part on the periphery of the sand mould and an internal working part of the sand mould;
the variable thickness part of the periphery of the sand mold is a sand mold with variable wall thickness;
the inner working part of the sand mould is a hollow shell.
Further preferably, the internal shape of the hollow housing is determined by the external shape of the casting.
Further preferably, the wall thicknesses of the hollow shells are equal, and the wall thickness of the hollow shell is greater than or equal to the thickness of the functional sand of the sand mold with the variable wall thickness.
Further preferably, the thickness of the functional sand is the minimum thickness for ensuring the mechanical property of the sand mold, namely the minimum thickness of the sand mold when the sand mold is not damaged or cracked in the alloy pouring process.
Preferably, the thickness of the bottom thickening sand box is thickened by corresponding thickness according to the volume of the casting, when the mass of the casting is less than 30kg, the thickness is increased by 10mm, when the mass of the casting is more than 30kg, the thickness is increased by 15mm, when the mass of the casting is more than 30kg, the thickness is less than 80kg, and the thickness is increased by 20mm, when the mass of the casting is more than 80 kg.
Compared with the prior art, the invention has the following beneficial effects:
the method adopts the 3DP process to manufacture the integral sand mold with the variable wall thickness structure, realizes the variable wall thickness design of the sand mold on the premise of ensuring that the mechanical strength of the sand mold meets the casting requirement, and breaks through the limitation that the traditional sand core casting outer sand box is a thick and large cubic structure; meanwhile, the 3D printing technology is adopted to solve the problems that the traditional sand mold preparation process can only prepare each part of a sand mold in a split mode and is difficult to prepare the sand mold with a complex structure and a variable wall thickness. The sand mold provided by the invention can effectively realize uniform heat dissipation of the sand mold, so that the cooling speed of each part is consistent when the alloy is solidified, the generation of casting defects is reduced, and the structural uniformity and the overall performance of a casting are improved; meanwhile, the invention can also reduce the volume of the sand mold, save the raw sand and reduce the cost. The concrete advantages are as follows:
1. the sand mold provided by the invention can effectively realize uniform heat dissipation of the sand mold, improve the temperature field uniformity in the casting solidification process, ensure that the cooling speed of each part is consistent when the alloy is solidified, reduce the generation of casting defects and improve the structure uniformity and the overall performance of the casting;
the 2.3 DP process can effectively realize the sand mold manufacturing of a complex structure and shape after the sand mold is locally thickened, avoids the manufacturing and processing processes of a mold in the traditional casting process, can shorten the production period and improve the production efficiency;
3. the integral sand mold prepared by the 3DP process avoids the core assembly process in the traditional hot core box process, and improves the precision of castings with complex structures, thereby improving the batch consistency and the yield of the castings;
4. the outer sand box is changed into a conformal design, the sand box is not a traditional cubic structure any more, the size of the sand mould is effectively reduced, raw sand is saved, the cost is reduced, meanwhile, the waste of resources and the environmental pollution are reduced, and the development trend of modern green casting is met.
The integral sand mold with the variable wall thickness structure is manufactured based on the manufacturing method, and the outer sand box of the sand mold comprises a sand mold peripheral variable wall thickness part and a sand mold internal working part of a casting sand mold. The variable wall thickness part on the periphery of the sand mold can be used for ensuring the uniform solidification temperature field of the casting, the working part in the sand mold is used for forming the appearance of the casting, the shape of the working part is determined by the appearance structure of the casting, and meanwhile, the strength of the sand mold is kept to prevent the casting from being broken under the action of casting pressure.
Drawings
FIG. 1 is a structural view of a sand mold in example 1;
FIG. 2 is a structural view of a sand mold in example 2;
wherein: 1. the inner working part of the sand mould, 2, the outer periphery of the sand mould, 3, and the bottom thickening part of the sand mould.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
The invention is described in further detail below with reference to the accompanying drawings:
example 1:
as shown in fig. 1, the variable thickness sand mold structure during casing casting comprises a sand mold inner working part 1 and a sand mold outer periphery variable thickness part 2; the sand mold internal working part 1 is a hollow shell, and the internal shape of the hollow shell is determined by the shape of shell parts; the variable thickness part 2 at the periphery of the sand mold is determined as the heat dissipation condition of the part; the inner working part 1 of the sand mould is connected with the outer variable thickness part 2 of the sand mould into a whole.
The specific implementation process is as follows: because the wall thickness of the casting is uneven, the heat dissipation of each part is uneven, and the outer part of the sand mould is designed into a variable wall thickness part 2 at the periphery of the sand mould, as shown in figure 1. In order to ensure that the core meets the strength requirement in the casting process, the wall thickness S of the internal working part 1 of the sand mold is selected to be more than or equal to the functional sand thickness S of the sand mold0The strength of the sand mold and the casting stress can be calculated according to the stress matching between the stress of the casting process to the wall thickness of the sand mold and the strength of the sand mold。
The thickness S of the functional sand of the sand mold0Is 9.95 mm.
The wall thickness of the working part 1 inside the sand mould is selected to be 10 mm.
Because the casting quality is less than 30kg in embodiment 1, in order to prevent the bottom structure of the sand mold from being broken when being impacted by molten metal, the bottom thickening structure of the sand mold is selected to be 10mm, so that the bottom structure thickness of the sand mold is 20mm (the thickness of the functional sand is 10mm, and the total thickness of the functional sand is 20 mm).
Example 2
FIG. 2 shows a variable thickness sand mold structure for casting parts of a transmission housing, which comprises a sand mold inner working part 1 and a sand mold outer periphery variable thickness part 2; the internal working part 1 of the sand mould is a hollow shell; the internal shape of the hollow shell is determined by the shape of the gearbox part; the variable thickness part 2 at the periphery of the sand mold is determined as the heat dissipation condition of the part; the inner working part 1 of the sand mould is connected with the outer variable thickness part 2 of the sand mould into a whole.
The specific implementation process is that in order to reduce the usage amount of sand during manufacturing of the sand mold and ensure uniform heat dissipation of all parts of the part in the casting process, the exterior of the sand mold is designed into a variable wall thickness part 2 on the periphery of the sand mold as shown in fig. 2. In order to ensure that the sand mold meets the strength requirement in the casting process, the wall thickness S of the internal working part 1 of the sand mold is selected to be more than or equal to the functional sand thickness S of the sand mold0°。
The thickness S of the functional sand of the sand mold0Is 14.46 mm.
The wall thickness of the sand mould internal working part 1 is selected to be 15 mm.
Because the mass of the casting in the embodiment 2 is more than 30kg and less than 60kg, in order to prevent the bottom structure of the sand mold from being damaged when being impacted by molten metal, the bottom thickening structure of the sand mold is selected to be 15mm, and the thickness of the bottom structure of the sand mold is 30 mm.
In summary, the sand mold structure design and manufacturing method for the targeted control of the microstructure of the casting, disclosed by the invention, manufactures the integral sand mold with the variable wall thickness structure through numerical simulation calculation and 3DP process design, and the outer sand box of the sand mold comprises the peripheral variable wall thickness part, the inner working part and the bottom thickened part of the casting sand mold. The peripheral wall thickness-variable structure can be used for ensuring the uniform solidification temperature field of the casting, the internal working part is used for forming the appearance of the casting, the shape of the internal working part is determined by the appearance structure of the casting, and meanwhile, the strength of the sand mold is kept to prevent the casting from being broken under the action of casting pressure. Compared with the prior art, the invention has the advantages that: on the basis of keeping the structure and the strength required by the sand mold work, the temperature field during alloy solidification is improved by changing the structure and the wall thickness of an external sand box, so that the cooling speed of each casting part is consistent, the casting defect is avoided, and the structure uniformity and the quality of a casting are improved; meanwhile, the outer sand box is changed into a conformal design, the sand box is not a traditional cubic structure any more, the volume of the sand mould is effectively reduced, the raw sand is saved, and the cost is reduced; in addition, the 3DP process can be adopted to form the integral sand mold with a complex structure, so that the precision, the batch consistency and the yield of castings with complex structures are improved.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.
Claims (10)
1. A design method of a variable wall thickness sand mold structure for controlling the microstructure of a casting in a targeted manner is characterized by comprising the following steps:
1) setting at least 5-10 temperature measurement areas on an outer sand box of a casting sand mold structure to be measured according to the change characteristics of the shape of the casting, and simulating and calculating the simulated temperature data of each temperature measurement area;
2) carrying out an actual casting experiment by adopting the casting sand mold structure to be measured, and measuring actual temperature data of each temperature measurement area in real time;
3) comparing and analyzing the simulated temperature data obtained in the step 1) and the actual temperature data actually measured in the step 2) at the same moment, if the relative temperature error of any temperature measuring point is more than 10%, increasing or decreasing the heat conduction coefficient and the radiation heat exchange coefficient by 10%, and then taking the values as new basic parameters;
4) repeating the steps 1) to 3) until the error between the temperature measuring point data obtained by the simulation calculation and the actually measured temperature at the same moment is less than 10% at all times, and obtaining basic parameters for the simulation calculation;
5) simulating and calculating solidification temperature fields of the outer sand box of the casting to be measured at different moments by using the simulated temperature data of the casting obtained in the step 1) and the basic parameters for simulation calculation obtained in the step 4);
6) analyzing the solidification temperature fields of the casting external sand box to be detected calculated in the step 5) at different moments, and judging whether a local supercooling temperature area exists or not; if the local supercooling region exists, thickening the outer sand box in the local supercooling temperature region, and repeating the steps 1) to 5) until the local supercooling temperature region does not exist; and when the temperature local supercooling area does not exist, storing the corrected thickness data of the outer sand box, namely designing the thickness data of the variable wall thickness sand mold structure.
2. The design method of the variable wall thickness sand mold structure of the microstructure of the targeted control casting according to claim 1, characterized in that in the step 1), ProCAST software is adopted to perform simulation calculation of simulation temperature according to the sand mold structure and alloy basic parameters; wherein, the sand mould structure and alloy basic parameters include: thermal conductivity, radiative heat transfer coefficient, specific heat, latent heat of solidification, density, and solid/liquidus temperature of the alloy.
3. The design method of the variable wall thickness sand mold structure for the targeted control of the microstructure of the casting according to claim 1, wherein in the step 2), actual temperature data of each temperature measurement area is measured in real time by adopting a thermocouple temperature measurement method.
4. An integral sand mold with a variable wall thickness structure is characterized in that the integral sand mold with the variable wall thickness structure is an integral structure consisting of an internal integral sand core, an external variable wall thickness sand box and a bottom thickening sand box;
the external variable-wall-thickness sand box is processed and manufactured by adopting the thickness data of the variable-wall-thickness sand mould structure obtained by the design method of any one of claims 1 to 3.
5. The variable wall thickness structural integral sand mold of claim 4, wherein the internal integral sand core is a sand core prepared by a 3DP process according to the casting structure to be measured.
6. The integrated sand mold with a variable wall thickness structure according to claim 4, wherein the external variable wall thickness sand box is formed by integrally connecting a peripheral variable wall thickness part of the sand mold with an internal working part of the sand mold;
the variable thickness part of the periphery of the sand mold is a sand mold with variable wall thickness;
the inner working part of the sand mould is a hollow shell.
7. A variable wall thickness structural integral sand mold in accordance with claim 6, wherein the internal shape of said hollow shell is determined by the external shape of the casting.
8. A unitary sand mold of variable wall thickness construction according to claim 6, wherein the wall thickness of the hollow shells is equal and greater than or equal to the functional sand thickness of the variable wall thickness sand mold.
9. The integral sand mold of a variable wall thickness structure according to claim 8, wherein the functional sand thickness is a minimum thickness that ensures the mechanical properties of the sand mold, i.e., a minimum sand mold thickness at which breakage or cracking of the sand mold does not occur during the alloy casting process of the sand mold.
10. The integral sand mold with the variable wall thickness structure according to claim 4, wherein the thickness of the bottom thickening sand box is increased by corresponding thickness according to the volume of the casting, when the mass of the casting is less than 30kg, the thickness is increased by 10mm, when the mass of the casting is more than 30kg, the thickness is increased by 15mm, when the mass of the casting is more than 80kg, and the thickness is increased by 20mm, when the mass of the casting is more than 80 kg.
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Cited By (2)
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| CN114101599A (en) * | 2021-10-29 | 2022-03-01 | 西峡县众德汽车部件有限公司 | Method for improving deformation of sand-lined iron mold sand-coated axle sand box |
| US11878343B2 (en) | 2021-12-07 | 2024-01-23 | Lockheed Martin Corporation | Housing and method of preparing same using a hybrid casting-additive manufacturing process |
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